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Automated camera inspection in Li-ion battery manufacturing

Allied Vision cameras are widely used in a variety of industrial processes. Lithium batteries are safety-critical products manufactured in more demanding processes to ensure that appropriate safety and quality standards are met.

In general, following procedures are involved in the Lithium-ion battery manufacturing: material preparation, electrode manufacturing, cell manufacturing, battery module assembly and battery pack assembly. 

Machine vision can be applied to each process step to improve product quality, reduce defect rate, and speed up automation efficiency. The typical requirements for machine vision solution in the lithium-ion battery industry are:

  • Industrial-grade quality and durability to deliver high quality imaging even under harsh environment
  • Affordable price to reduce overall system cost
  • High sensitivity and resolution for high-precision defect detection
  • High frame rates for high-speed imaging ensuring high throughput and productivity
  • Excellent connectivity to eliminate the risk of lost frames and missed defects

 

 

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Examples of vision applications in battery production

Stacking/Winding

Stacking and winding are two common lithium battery manufacturing methods to create flat or cylindrical cells. In both cases, the two electrodes (anode and cathode) are assembled with an isolating separator in-between. Machine vision cameras can be used to check the accurate position of each component and ensure that both electrodes are perfectly isolated from each other.

Sealing

The dried battery cell will be secured in the battery case and injected with electrolyte, it must be sealed to ensure the positive and negative poles in the cell are not in contact and avoid electrolyte leaks. The main application of machine vision in this process is to monitor the sealing process and to detect whether the seal is intact after the sealing is completed.

Packaging

Packaging is the last procedure in the lithium battery manufacturing process. High-quality packaging ensures that lithium batteries are not physically damaged during transport and usage, thus preventing safety accidents. The unique serial number of each single lithium battery is recorded to allow effective tracing of the product life cycle for after-sales and warranty services. Machine vision cameras are also widely used in lithium battery packaging and storage processes, including detecting the intact appearance of packaging, scanning QR codes or OCR recognition.

Recommended cameras for battery production inspection

Mako Series - Small and affordable

  • Small 29x29mm footprint for easy hardware integration
  • High value for money: Industrial quality at attractive price
  • Up to 286 frames per second for high-speed inspection
  • GigE Vision interface for secured data transfer over long distances

Recommended Camera Models

Manta Series - Freedom of choice

  • Largest choice of sensors to meet any requirement
  • Modular hardware adapts to system configuration
  • Up to 12.4 MPixel resolution for high-precision inspection
  • GigE Vision interface for secure data transfer over long distances
Camera ModelMako G-131Mako G-192Mako G-503  Mako G-507Manta G-895
Sensor

EV 76C560

EV 76C560MT9P031/P006IMX264IMX267
Mega-Pixcels1.3 MP1.9 MP5.0 MP5.0 MP8.9MP
Resolution1280 x 10241600 x 12002592 × 19442464 x 20564112 x 2176
Pixel Size5.3 x 5.34.5 x 4.52.2 x 2.23.45 x 3.453.45 x 3.45
Sensor Size1/1.8'' CMOS1/1.8'' CMOS1/2.5'' CMOS2/3'' CMOS1'' CMOS
Shutter

Rolling/Global/

Global Reset

Rolling/Global/

Global Reset

Rolling/Global ResetGlobalGlobal
Frame Rate62601423.713.4
Lens MountC-MountC-MountC-MountC-MountC-Mount